蝶阀后管线腐蚀发生与发展机制研究

doi:10.11949/0438-1157.20221209

摘要/Abstract

摘要：

针对某石化厂蝶阀后管线异常减薄的问题，结合腐蚀分析、腐蚀实验和数值模拟，分析了管线异常减薄的原因，研究了腐蚀的发生与发展机制。样品的结构及成分通过扫描电镜（SEM）、X射线衍射（XRD）和能谱仪（EDS）及金相显微镜进行表征，并结合计算流体动力学（CFD）分析了流场参数对腐蚀过程的影响。结果表明，管线主要的失效原因是流动加速腐蚀。此外，基于速度边界层与壁面粗糙度之间的关系，将蝶阀后管线划分为三个不同的区域，并用示意图对不同区域腐蚀的发生与发展机制进行了解释。

关键词: 管线, 腐蚀, 计算流体力学, 电化学, 流动

Abstract:

Aiming at the abnormal thinning of the pipeline behind the butterfly valve in a petrochemical plant, combined with corrosion analysis, corrosion test and numerical simulation, the causes of abnormal thinning of the pipeline were analyzed, and the occurrence and development mechanism of corrosion were studied. The structure and composition of the samples were characterized by scanning electron microscope (SEM), X-ray diffraction (XRD), energy spectrometer (EDS) and metallographic microscope. The influence of flow field parameters on corrosion process was calculated and analyzed based on computational fluid dynamics (CFD). The results show that the main failure reason is flow accelerated corrosion. In addition, the pipeline behind the butterfly valve is divided into three different areas based on the relationship between velocity boundary layer and wall roughness, and the occurrence and development mechanism of corrosion in different areas are explained by schematic diagrams.

Key words: pipeline, corrosion, computational fluid dynamics, electrochemistry, flow

中图分类号:

TE 969

苏国庆, 张建文, 李彦. 蝶阀后管线腐蚀发生与发展机制研究[J]. 化工学报, 2022, 73(12): 5504-5516.

Guoqing SU, Jianwen ZHANG, Yan LI. Study on the occurrence and development mechanism of pipeline corrosion behind butterfly valve[J]. CIESC Journal, 2022, 73(12): 5504-5516.

图/表 22

图1 蝶阀结构和阀后管线壁面划分

Fig.1 Butterfly valve structure and pipe wall division

Table 2 Composition of conveying medium

组成	含量/%(mass)
H₂O	18
C₃	0.06
C₄	0.31
C₅	1.25
C₆	6.85
C₇	15.05
C₈	25.34
C₉	24.23
C₁₀	8.23
C₁₁	0.64
H₂S	0.0272
Cl^-	0.006

表2　输送介质组成

图2 样品实物图

Fig.2 Physical map of samples

图3 厚度分布

Fig.3 Thickness distribution

图4 样品扫描电镜图像

Fig.4 SEM images of samples

图5 样品能谱分析结果

Fig.5 EDS spectrums of samples

图6 样品XRD谱图

Fig.6 XRD patterns of samples

表3 304不锈钢试样化学成分

Table 3 Chemical composition of 304 stainless steel coupons

元素	含量/%(mass)
C	0.03
Mn	1.22
P	0.02
S	0.02
Si	0.31
Cr	18.90
Ni	9.10
Fe	70.4

图7 实验装置示意图

Fig.7 Schematic diagram of experimental device

图8 试样的宏观形貌

Fig.8 Morphology structure of specimen

图9 试样的微观形貌

Fig.9 Micromorphology of specimen

图10 蝶阀计算域及网格划分

Fig.10 Computational domain and mesh division of butterfly valve

表4 模拟的边界条件

Table 4 Simulated boundary conditions

参数	数值
入口流速/(m/s)	1.5
介质密度/(kg/m³)	790
介质黏度/cP	0.43
压力/MPa	0.15

图11 不同数量网格下左壁面的切应力分布

Fig.11 Wall shear distribution of left wall at different number of meshes

图12 截面位置示意图

Fig.12 Schematic diagram of section position

图13 不同截面的速度云图

Fig.13 Velocity nephogram of different sections

图14 不同截面的流线分布

Fig.14 Streamline distribution of different sections

图15 不同开度下的切应力分布

Fig.15 Wall shear distribution at different opening degrees

图16 不同壁面粗糙度下的切应力分布

Fig.16 Wall shear distribution at different wall roughness

表5 不同粗糙度下的流动类型

Table 5 Flow types at different roughness

e/mm	流动类型
0≤e≤0.08	水力光滑管
0.08<e<0.85	过渡区圆管
e≥0.85	完全粗糙管

图17 蝶阀后管线腐蚀发生与发展机制示意图

Fig.17 Schematic diagram of occurrence and development mechanism of pipeline corrosion behind butterfly valve

参考文献 32

1	韦彦强, 何世权. 三偏心蝶阀的结构优化及流场分析[J]. 液压与气动, 2021, 45(12): 162-167.
	Wei Y Q, He S Q. Structural optimization and flow field analysis of triple-eccentric butterfly valve[J]. Chinese Hydraulics & Pneumatics, 2021, 45(12): 162-167.
2	何庆中, 刘玉聪, 赵献丹, 等. 基于CFD动网格技术的三偏心蝶阀开启特性[J]. 排灌机械工程学报, 2019, 37(6): 508-512.
	He Q Z, Liu Y C, Zhao X D, et al. Opening characteristics of triple eccentric butterfly valve based on CFD moving grid technology[J]. Journal of Drainage and Irrigation Machinery Engineering, 2019, 37(6): 508-512.
3	Toro A D, Johnson M C, Spall R E. Computational fluid dynamics investigation of butterfly valve performance factors[J]. Journal - American Water Works Association, 2015, 107(5): E243-E254.
4	张松, 但志宏, 李腾, 等. 大口径蝶阀数学建模与流场特性分析[J]. 航空动力学报, 2020, 35(6): 1315-1325.
	Zhang S, Dan Z H, Li T, et al. Modeling and flow field analysis of large-diameter butterfly valve[J]. Journal of Aerospace Power, 2020, 35(6): 1315-1325.
5	Lee M G, Lim C S, Han S H. Shape design of the bottom plug used in a 3-way reversing valve to minimize the cavitation effect[J]. International Journal of Precision Engineering and Manufacturing, 2016, 17(3): 401-406.
6	Song X G, Wang L, Baek S H, et al. Multidisciplinary optimization of a butterfly valve[J]. ISA Transactions, 2009, 48(3): 370-377.
7	Kodura A. An analysis of the impact of valve closure time on the course of water hammer[J]. Archives of Hydro-Engineering and Environmental Mechanics, 2016, 63(1): 35-45.
8	Wang H M, Hu F, Kong X S, et al. Pressure fluctuation of steam on the disc in a triple eccentric butterfly valve[J]. SN Applied Sciences, 2020, 2(7): 1-10.
9	诸葛伟林, 刘光临, 蒋劲, 等. 蝶阀三维分离流动的数值模拟研究[J]. 流体机械, 2003, 31(6): 14-16.
	Zhuge W L, Liu G L, Jiang J, et al. Numerical investigation on 3-D separate flow of butterfly valve[J]. Fluid Machinery, 2003, 31(6): 14-16.
10	Kan B, Chen L J. Numerical analysis of flow field in link rod butterfly valve for high-temperature steam[J]. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2020, 42(4): 1-11.
11	Hosseini R K, Yareiee S. Failure analysis of a nickel aluminium bronze butterfly valve in a seawater line[J]. Engineering Failure Analysis, 2021, 129: 105686.
12	谢金宏. 双偏心蝶阀开裂失效分析[J]. 金属热处理, 2019, 44(S1): 60-63.
	Xie J H. Failure analysis of the valve plate and valve body[J]. Heat Treatment of Metals, 2019, 44(S1): 60-63.
13	Liu B, Zhao J G, Qian J H. Numerical analysis of cavitation erosion and particle erosion in butterfly valve[J]. Engineering Failure Analysis, 2017, 80: 312-324.
14	李杰, 高嘉喜, 崔铭伟, 等. 腐蚀对管输CO₂压力损失影响分析[J]. 表面技术, 2016, 45(8): 45-49.
	Li J, Gao J X, Cui M W, et al. Effect of corrosion on pressure loss of CO₂ pipeline[J]. Surface Technology, 2016, 45(8): 45-49.
15	Hamada E, Yamada K, Nagoshi M, et al. Direct imaging of native passive film on stainless steel by aberration corrected STEM[J]. Corrosion Science, 2010, 52(12): 3851-3854.
16	Gui Y, Zheng Z J, Gao Y. The bi-layer structure and the higher compactness of a passive film on nanocrystalline 304 stainless steel[J]. Thin Solid Films, 2016, 599: 64-71.
17	Jiang R J, Wang Y W, Wen X, et al. Effect of time on the characteristics of passive film formed on stainless steel[J]. Applied Surface Science, 2017, 412: 214-222.
18	Feng Z C, Cheng X Q, Dong C F, et al. Passivity of 316L stainless steel in borate buffer solution studied by Mott-Schottky analysis, atomic absorption spectrometry and X-ray photoelectron spectroscopy[J]. Corrosion Science, 2010, 52(11): 3646-3653.
19	Davoodi A, Pakshir M, Babaiee M, et al. A comparative H₂S corrosion study of 304L and 316L stainless steels in acidic media[J]. Corrosion Science, 2011, 53(1): 399-408.
20	Ding J H, Zhang L, Lu M X, et al. The electrochemical behaviour of 316L austenitic stainless steel in Cl^- containing environment under different H₂S partial pressures[J]. Applied Surface Science, 2014, 289: 33-41.
21	Bai P P, Zhao H, Zheng S Q, et al. Initiation and developmental stages of steel corrosion in wet H₂S environments[J]. Corrosion Science, 2015, 93: 109-119.
22	潘佩媛, 陈衡, 焦健, 等. 湿法脱硫后烟气腐蚀现场实验研究[J]. 化工学报, 2019, 70(1): 161-169.
	Pan P Y, Chen H, Jiao J, et al. In-plant experimental study on desulfurized flue gas corrosion[J]. CIESC Journal, 2019, 70(1): 161-169.
23	李自力, 程远鹏, 毕海胜, 等. 油气田CO₂/H₂S共存腐蚀与缓蚀技术研究进展[J]. 化工学报, 2014, 65(2): 406-414.
	Li Z L, Cheng Y P, Bi H S, et al. Research progress of CO₂/H₂S corrosion and inhibitor techniques in oil and gas fields[J]. CIESC Journal, 2014, 65(2): 406-414.
24	张建文, 苏国庆, 姜爱国. 液化气脱硫装置再生塔返塔管线弯头腐蚀失效机制分析[J]. 化工学报, 2018, 69(8): 3537-3547.
	Zhang J W, Su G Q, Jiang A G. Corrosion failure mechanism of return pipeline elbow of regeneration tower in LPG desulfurization unit[J]. CIESC Journal, 2018, 69(8): 3537-3547.
25	Fierro G, Ingo G M, Mancia F. XPS investigation on the corrosion behavior of 13Cr- martensitic stainless steel in CO₂-H₂S-Cl^-environment[J]. Corrosion, 1989, 45(10): 814-823.
26	Barmatov E, Hughe T, Nagl M. Efficiency of film-forming corrosion inhibitors in strong hydrochloric acid under laminar and turbulent flow conditions[J]. Corrosion Science, 2015, 92: 85-94.
27	谭卓伟, 杨留洋, 王振波, 等. 高剪切力流场下X80管线钢局部腐蚀深坑诱导局部湍流交互机理研究[J]. 化工学报, 2021, 72(4): 2203-2212.
	Tan Z W, Yang L Y, Wang Z B, et al. Study on interaction mechanism of local turbulent flow induced by local corrosion of X80 pipeline steel in high shear flow field[J]. CIESC Journal, 2021, 72(4): 2203-2212.
28	张凌翔, 周克毅, 徐奇, 等. 90°弯管流动加速腐蚀的实验和数值模拟[J]. 化工学报, 2018, 69(12): 5173-5181.
	Zhang L X, Zhou K Y, Xu Q, et al. Experiment and numerical simulation of flow-accelerated corrosion of 90° elbow[J]. CIESC Journal, 2018, 69(12): 5173-5181.
29	Xu Y Z, Tan M Y. Probing the initiation and propagation processes of flow accelerated corrosion and erosion corrosion under simulated turbulent flow conditions[J]. Corrosion Science, 2019, 151: 163-174.
30	何昌春, 徐磊, 陈伟, 等. 常顶系统流动腐蚀机理预测及防控措施优化[J]. 化工学报, 2019, 70(3): 1027-1034.
	He C C, Xu L, Chen W, et al. Mechanism prediction of flow-induced corrosion and optimization of protection measures in overhead system of atmospheric tower[J]. CIESC Journal, 2019, 70(3): 1027-1034.
31	陈涛, 张国亮. 化工传递过程基础[M]. 3版. 北京: 化学工业出版社, 2009: 111-113.
	Chen T, Zhang G L. Chemical Engineering Transfer Processes[M]. 3rd ed. Beijing: Chemical Industry Press, 2009: 111-113.
32	彭文山, 刘雪键, 刘少通, 等. 含砂流动海水中Q235钢冲刷腐蚀行为研究[J]. 表面技术, 2019, 48(9): 230-237.
	Peng W S, Liu X J, Liu S T, et al. Erosion-corrosion behavior of Q235 steel in flowing seawater containing sand particles[J]. Surface Technology, 2019, 48(9): 230-237.

编辑推荐 0

Metrics

阅读次数

全文

573

HTML			PDF

最新录用	在线预览	正式出版	最新录用	在线预览	正式出版
0	0	15	2	0	556

来源	本网站	其他网站

次数	80	493
比例	14%	86%

摘要

264

最新录用	在线预览	正式出版

12	0	252

来源	本网站	其他网站

次数	146	118
比例	55%	45%

[1]	张思雨, 殷勇高, 贾鹏琦, 叶威. 双U型地埋管群跨季节蓄热特性研究[J]. 化工学报, 2023, 74(S1): 295-301.
[2]	肖明堃, 杨光, 黄永华, 吴静怡. 浸没孔液氧气泡动力学数值研究[J]. 化工学报, 2023, 74(S1): 87-95.
[3]	宋瑞涛, 王派, 王云鹏, 李敏霞, 党超镔, 陈振国, 童欢, 周佳琦. 二氧化碳直接蒸发冰场排管内流动沸腾换热数值模拟分析[J]. 化工学报, 2023, 74(S1): 96-103.
[4]	周绍华, 詹飞龙, 丁国良, 张浩, 邵艳坡, 刘艳涛, 郜哲明. 短管节流阀内流动噪声的实验研究及降噪措施[J]. 化工学报, 2023, 74(S1): 113-121.
[5]	张义飞, 刘舫辰, 张双星, 杜文静. 超临界二氧化碳用印刷电路板式换热器性能分析[J]. 化工学报, 2023, 74(S1): 183-190.
[6]	康飞, 吕伟光, 巨锋, 孙峙. 废锂离子电池放电路径与评价研究[J]. 化工学报, 2023, 74(9): 3903-3911.
[7]	温凯杰, 郭力, 夏诏杰, 陈建华. 一种耦合CFD与深度学习的气固快速模拟方法[J]. 化工学报, 2023, 74(9): 3775-3785.
[8]	王玉兵, 李杰, 詹宏波, 朱光亚, 张大林. R134a在菱形离散肋微小通道内的流动沸腾换热实验研究[J]. 化工学报, 2023, 74(9): 3797-3806.
[9]	程业品, 胡达清, 徐奕莎, 刘华彦, 卢晗锋, 崔国凯. 离子液体基低共熔溶剂在转化CO₂中的应用[J]. 化工学报, 2023, 74(9): 3640-3653.
[10]	岳林静, 廖艺涵, 薛源, 李雪洁, 李玉星, 刘翠伟. 凹坑缺陷对厚孔板喉部空化流动特性影响研究[J]. 化工学报, 2023, 74(8): 3292-3308.
[11]	邢雷, 苗春雨, 蒋明虎, 赵立新, 李新亚. 井下微型气液旋流分离器优化设计与性能分析[J]. 化工学报, 2023, 74(8): 3394-3406.
[12]	陈佳起, 赵万玉, 姚睿充, 侯道林, 董社英. 开心果壳基碳点的合成及其对Q235碳钢的缓蚀行为研究[J]. 化工学报, 2023, 74(8): 3446-3456.
[13]	汪林正, 陆俞冰, 张睿智, 罗永浩. 基于分子动力学模拟的VOCs热氧化特性分析[J]. 化工学报, 2023, 74(8): 3242-3255.
[14]	胡亚丽, 胡军勇, 马素霞, 孙禹坤, 谭学诣, 黄佳欣, 杨奉源. 逆电渗析热机新型工质开发及电化学特性研究[J]. 化工学报, 2023, 74(8): 3513-3521.
[15]	张琦钰, 高利军, 苏宇航, 马晓博, 王翊丞, 张亚婷, 胡超. 碳基催化材料在电化学还原二氧化碳中的研究进展[J]. 化工学报, 2023, 74(7): 2753-2772.